Disposable absorbent article employing an absorbent composite and method of making the same

ABSTRACT

A disposable absorbent article includes a topsheet, a backsheet and an absorbent core disposed therebetween. One or more of the backsheet, topsheet, and absorbent core is constructed of an absorbent composite that includes an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof and super absorbent polymer (SAP) particles bonded together by the hydratable fibers, and a nonwoven substrate supporting the absorbent layer such as SMS. The absorbent layer is coated over the surface of the nonwoven substrate. The core may include one uniform layer of the absorbent composite or a composite having one layer of the nonwoven substrate and a plurality of segmented absorbent layers applied thereon. In the latter design, the absorbent layers are spaced apart from one another to expose surface sections of the substrate. These non-coated surface sections provide wicking zones which allow room for the absorbent layers to expand and prevent gel blocking.

BACKGROUND OF THE INVENTION

[0001] The present application claims the benefit of the filing date ofU.S. provisional application Ser. No. 60/144,345 filed Jul. 16, 1999(which is hereby incorporated by reference for all purposes).

[0002] The present invention relates generally to a disposable absorbentarticle or garment that employs an absorbent composite as one or more ofits structural components. Disposable absorbent articles or garmentscontemplated by the invention include diapers, training pants, adultincontinence products, feminine hygiene products, and other similar useabsorbent products (collectively “disposable absorbent articles”). Theuse of disposable diapers and training pants has surpassed the use ofcloth diapers. Disposable feminine hygiene products are popular becausethese offer improved comfort and utility to the wearer. Disposableincontinence products, on the other hand, are intended for adults andprovide these wearers control and absorption of involuntary bowel andbladder discharge associated with some medical conditions, includingthose associated with advancing age.

[0003] Prior art disposable absorbent articles typically employ threebasic structural elements: a fluid permeable topsheet that is placednext to the wearer's skin when the article is worn, a backsheet whichforms the outer surface of the diaper, and an absorbent elementinterposed between the topsheet and the backsheet. The permeabletopsheet is designed to allow liquid to pass from the area adjacent thewearer into the area of the core. Topsheets may be constructed from awide range of liquid and vapor permeable hydrophilic material, and maybe used with surface activation agents (“surfactants”) to increase itsliquid permeability. Surfactants lower the surface tension of the liquidand facilitates the liquid's passage through the topsheet.

[0004] The backsheet is typically vapor and liquid impermeable so as tominimize or prevent leakage. For example, the backsheet is often animpermeable film that extends the full width of the article. In some ofthe more recent designs, a cloth-like outer sheet is added to the filmfor a more pleasing feel, as the film is positioned to cover only thecentral portion of the backsheet, and/or in the area most likely to beexposed to liquid. In either design, the film may be made so as to beimpermeable or to have some vapor transmission-properties, or“breathability,” and functions to contain fluids within the absorbentelement. Such a two-layer backsheet design, however, contributes to thecomplexity of any manufacturing process. The articles further include amiddle layer of a moisture absorbent core between the topsheet andbacksheet. The absorbent core must be able to take up the liquid whichpasses through the topsheet, and distribute the liquid. The core isdesigned to retain the distributed liquid.

[0005] A typical absorbent core of the prior art is constructed of twocomponents: a high or super absorbent material and an absorbent matrix.Common sources of absorbent materials include numerous compounds oforganic materials such as polyvinyl alcohol, polyacrylates, variousgrafted starches, and cross-linked sodium polyacrylate. These absorbentmaterials are employed as core material in the form of particles,fibers, foams, and/or layers. The absorbent matrix, on the other hand,is typically provided by de-fiberized wood pulp or similar material. Asexpected, the majority volume of a prior art absorbent core is taken upby the absorbent matrix and not the absorbent material.

[0006] The two-component core design is used primarily because many ofthe preferred high absorbent materials are incapable of absorbing liquidat the rate or even near the rate at which liquid is typically receivedby the absorbent article (when worn). Therefore, the absorbent matrix isprovided to hold the received liquid and deliver it to the highabsorbency material at a rate slower than the rate at which the liquidwould otherwise be delivered (absent the absorbent matrix). This allowsthe high absorbent material more time to fully absorb the liquid.

[0007] Another function of the absorbent matrix is to prevent “gelblocking.” Gel blocking is the blockage of the interstitial spacesbetween elements or particles of the high absorbent material andblockage of channels through which the liquid must pass to encounterunsaturated absorbent particles. Such gel blocking can occur as a resultof the high absorbency particles or elements swelling upon absorption ofliquid and occupying additional volume. The fibers of the matrix prevent“gel blocking” by dispersing the high absorbent particles throughout thematrix, thereby minimizing the potential for particle-to-particlecontact.

[0008] Although the absorbent matrix does not have the high absorptionproperties of the high absorbent material, it is recognized as anecessary component in achieving adequate absorbency (measured by bothcapacity and rate) in prior art core compositions. Achieving optimalabsorbency in these core compositions involves not only selecting asuitable high absorbent material, but also identifying the optimal ratiobetween the high absorbent material and the absorbent matrix. Since theSAP material is typically 2-10 times more absorbent than the pulpmaterial (of the absorbent matrix), one means of providing a thinner,more compact absorbent core is to increase its SAP content and decreaseits pulp content. The ratio of SAP content to pulp content is, however,limited by the propensity of higher SAP/pulp ratio compositions to gelblock during use. It is generally accepted that an SAP/pulp ratio of 1is the highest, practical ratio available. Accordingly, this ratio alsosets the lower practical limit of the core thickness and thus, of thedisposable absorbent article.

SUMMARY OF THE INVENTION

[0009] It is, therefore, one of multiple objects of the invention toprovide a disposable absorbent article or garment employing an improvedabsorbent composite therein. According to the invention, such anabsorbent composite may be employed as a primary component of theabsorbent core, backsheet, topsheet, containment walls or cuffs, andother elements (e.g., an acquisition layer) of the disposable absorbentarticle, or a combination of two or more of these elements, therebyproducing an absorbent article having various advantageouscharacteristics. Among some of the characteristics which may beexhibited by the inventive disposable absorbent article are improved fitand appearance, improved absorption and liquid containment properties,simpler, more efficient manufacturing process, reduction of componentsand material sources, and a thinner, more compact construction.

[0010] A disposable absorbent article according to the inventionincludes a topsheet, a backsheet, and an absorbent core disposedtherebetween. At least one of the backsheet, topsheet, and absorbentcore and/or a combination of these elements (e.g., a backsheet/absorbentcore composite or topsheet/absorbent core composite) utilizes anabsorbent composite. The absorbent composite is constructed of anabsorbent layer (e.g, a low-density layer) of hydratable fine fibers inthe form of microfibril obtained from cellulose or a derivative thereof,and absorbent polymer (i.e., SAP) particles bonded together by thehydratable fibers, and a nonwoven substrate (e.g., a high-density layer)supporting the absorbent layer. The absorbent layer is coated upon thenonwoven substrate.

[0011] Containment walls including leg cuffs or leg gathers may alsoutilize the absorbent composite. For example, the article may employ apair of longitudinally-extending, upstanding cuffs spaced laterally fromthe core. Each cuff includes a folded portion of the topsheet and alongitudinally-extending absorbent composite secured within the foldedportion. The longitudinally-extending absorbent composite also includesan absorbent layer of hydratable fine fibers in the form of microfibriland super absorbent polymer (SAP) particles bonded together by thehydratable fibers and a nonwoven substrate supporting the absorbentlayer. In one set of embodiments, the core also includes an absorbentcomposite, and the core's absorbent composite and the longitudinallyextending absorbent composites of the cuffs are sections of onecontinuous absorbent composite structure. This composite structure ispositioned about a crotch region of the article and may be adapted(e.g., by selecting appropriate SAP material specifications) to swellupon wetting so as to substantially gel-block and liquid seal the crotchregion. Further, a nonwoven section of the topsheet may provide thenonwoven substrate of the absorbent composite of the containment wallsand/or of the absorbent core.

[0012] In another aspect of the invention, a backsheet utilizing theabsorbent composite preferably includes a low cross link SAP that isadapted to gel block upon wetting. In this way, the backsheet isbreathable when dry but the absorbent layer and, thus, the backsheet, issubstantially impervious when wet. Such a low cross-link SAP may be alow gel strength SAP having free swell capacities greater than about 40g/g SAP.

[0013] In yet another aspect of the invention and in one set ofembodiments, the absorbent core may be formed from a prefabricated sheetof the absorbent composite. In one embodiment, the absorbent compositehas a plurality of absorbent layers (e.g., segmented) which are spacedapart from one another such that non-coated surface sections of thesubstrate are exposed therebetween. The non-coated surface sections formwicking zones between the absorbent layers and allow the absorbentlayers room to swell, thereby preventing or minimizing gel blocking andpromoting saturation of the absorbent layers. The segments of absorbentlayers may be laterally spaced, elongated segments, randomly or equallydispersed (e.g., a staggered pattern) concentrations in dotted orrounded forms, or some other configuration. Preferably, the layers areconcentrated or enlarged at the crotch region of the disposableabsorbent article.

[0014] In one embodiment, the absorbent composite layer of the core hasa corrugated configuration. This configuration is characterized by aplurality of pleats (i.e., pronounced fold lines) wherein distinctadjacent sections of the absorbent composite mutually adhere. In anotherembodiment, the absorbent composite is rolled about a concentration ofpulp material such that the pulp concentration is disposed between twolayers of the absorbent composite (i.e., “nested”). Further embodimentsmay utilized a multi-tiered design wherein two or more absorbentcomposites or two or more absorbent layers are stacked (e.g., at leastin the crotch region).

[0015] In yet another aspect of the invention, the absorbent compositeforms the backsheet and the absorbent core. For example, the nonwovensubstrate forms or is provided by the backsheet and the absorbent layeris concentrated at the crotch region to form the absorbent core.Similarly, the absorbent composite may be utilized to form at least aportion of the topsheet and the absorbent core, wherein a section of thetopsheet provides the nonwoven substrate of the absorbent composite andthe absorbent layer forms the core.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] A better understanding of the invention may be obtained by when adetailed description of the preferred embodiments is considered inconjunction with the appended drawings, in which:

[0017]FIG. 1 is a vertical cross-section illustration of a prefabricatedabsorbent composite employed in the invention;

[0018]FIG. 2 is a perspective view of a disposable absorbent articleembodying the invention;

[0019]FIG. 3 is a top plan view of the disposable absorbent article ofFIG. 2 in a flat and extended condition;

[0020]FIG. 4 is an exploded view of the disposable article of FIG. 2;

[0021]FIG. 5 is a vertical cross sectional view across a core or crotchregion of an alternative disposable absorbent article according to theinvention;

[0022]FIG. 6 is a vertical cross-sectional view of the article in FIG. 5depicting the article when the absorbent core is wetted or activated;

[0023]FIG. 7 is a plan view illustration of an absorbent core employedby an absorbent article according to the present invention;

[0024]FIG. 8 is a plan view illustration of an absorbent core employedby an alternative absorbent article according to the present invention;

[0025]FIG. 9 is a plan view illustration of an absorbent core employedby another alternative absorbent article according to the invention;

[0026]FIG. 10 is a vertical cross-sectional view schematic of analternative absorbent article according to the invention;

[0027]FIG. 11 is a vertical cross-sectional view schematic of analternative absorbent core employed by an absorbent article according tothe invention;

[0028]FIG. 12 is a vertical cross-sectional view schematic of analternative absorbent core employed by an absorbent article according tothe invention;

[0029]FIG. 13 is a vertical cross-sectional view schematic of analternative embodiment of a disposable absorbent article according tothe invention;

[0030]FIG. 14 is a vertical cross-sectional view schematic of thedisposable absorbent article of FIG. 13 depicted in the “wet” condition;

[0031]FIG. 15 is a vertical cross-sectional view schematic of analternative embodiment of a disposable absorbent article according tothe present invention;

[0032]FIG. 16 is a vertical cross-sectional view schematic of thedisposable absorbent article of FIG. 15 depicted in the “wet condition;”

[0033]FIG. 17 is a vertical cross-sectional view schematic of abacksheet/absor core composite employed by an absorbent articleaccording to the invention;

[0034]FIG. 18 is a vertical cross-sectional view schematic of analternative backsheet/absorbent core composite employed by an absorbentarticle according to the invention;

[0035]FIG. 19 is a vertical cross-sectional view schematic of analternative backsheet/absorbent core composite employed by an absorbentarticle according to the invention.

[0036]FIG. 20 is a vertical cross-sectional schematic of atopsheet/absorbent core composite structure employed by an absorbentarticle according to the invention;

[0037]FIG. 21 is a schematic illustration of the construction of atopsheet/absorbent core composite structure employed by an absorbentarticle according to the invention;

[0038]FIG. 22 is a schematic of a vertical cross-sectional view of acontainment wall/absorbent core composite structure employed by anabsorbent article according to the invention;

[0039]FIG. 23 is a schematic of a vertical cross-sectional view of analternative containment wall/absorbent core composite structure employedby an absorbent article according to the invention; and

[0040]FIG. 24 is an alternative schematic of a vertical cross-sectionalview of an alternative containment wall/absorbent core compositestructure employed by an absorbent article according to the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

[0041] Upon review of the detailed description and the accompanyingdrawings provided herein, it will be apparent to one of ordinary skillin the art that the present invention is also applicable to otherdisposable absorbent articles and more particularly, to disposableabsorbent articles such as training pants or other incontinenceproducts. Accordingly, the present invention shall not be limited to thestructures and processes specifically described and illustrated herein,although the following description is particularly directed to adisposable diaper. The term “absorbent article” or “absorbent garment”with which the present invention is associated, includes various typesof disposable articles and garments which are placed against or inproximity to the body of the wearer so as to absorb and contain variousbodily exudates.

[0042]FIG. 1 depicts (in exaggerated fashion for illustration) anabsorbent composite 200 employed in various embodiments of the presentinvention. The absorbent composite 200 is a prefabricated sheetconstructed from water-swellable bodies in the form of super absorbentpolymer particles 202 (SAP) which are covered or intermixed withextremely fine micro-fibrillated cellulose 204 (MFC) and embedded intothe pores of a low-density nonwoven substrate 206 and anchored thereto(i.e., the MFC acts as a binder). As shown in FIG. 1, the prefabricatedabsorbent composite 200 includes a low density layer 208 of the SAP andMFC, and a high-density layer 210 of the nonwoven substrate 206. Aprocess of manufacturing a prefabricated sheet of the absorbentcomposite 200 suitable for the present invention has been developed bythe Japan Absorbent Technology Institute (JATI), and is availabletherefrom under the trade name MEGATHIN. The details of themanufacturing process and other characteristics of the MEGATHIN sheetare described in a PCT international application filed by JATI andissued Reference No. PCT/JP/97/0460 The disclosure provided in this andrelated applications by JATI are hereby incorporated by reference.

[0043] In summary, a suitable method of making the absorbent composite(as disclosed in JATI's PCT application) involves dispersing waterswellable solid bodies (i.e., the SAP particles) and the hydratablefibers of MFC in a dispersing medium of organic solvent and water. Theorganic solvent is selected such that it is capable of controlling theswelling of the SAP and dispersing the hydratable fibers and, thus,being miscible with water. The method further involves separating theSAP and fibers from the resultant dispersion liquid in the dispersingmedium (e.g, forming a layer of a resultant slurry and spreading theslurry layer over a supporting sheet). Then, the dispersing medium isremoved (e.g, from the slurry layer) and the remaining composite dried.

[0044] In one aspect of the invention, the invention provides variousadaptations of the absorbent composite manufactured, at least partially,by the above-described process. In another aspect of the invention, aplurality of absorbent composites having an array of properties areobtained for implementation in a disposable absorbent article and asvarious components of the inventive article, including as components ofthe backsheet, topsheet, absorbent core, containment walls or cuffs(including leg gathers), backsheet/absorbent core composite,topsheet/absorbent composite, and other combinations of these elements.

[0045] In one aspect of the invention, multiple functions oradvantageous properties are obtained in a single prefabricated absorbentcomposite sheet structure (suitable for a specific disposable absorbentarticle design) by varying the basis weight of the SAP and/or thenonwoven substrate, varying the compositions of the low density layerand the nonwoven substrate, varying the detailed construction of thecomponents such as, for example, the degree of SAP cross-linking, and/orapplying the absorbent composite at various locations in the article orintegrating same with various elements of the article. Specific examplesof these variations are provided in more detail in the description ofthe individual components of the inventive article.

[0046] Generally, a higher or faster absorption rate for the SAP (andthus, for the absorbent composite sheet) is achieved by providing an SAPstructure with a lower degree of cross-linking construction, whereas alower or slower absorption rate is achieved by providing an SAPstructure with a higher degree of cross-linking construction. The degreeof cross-linking (both internally and at the surface of the SAPstructure) affects the gross absorbent properties of the SAP includinggel strength and AUL (absorbency under load measured at the standard0.28 psi). It is contemplated that the optimal degree of cross-linkingand SAP absorption rate for a particular disposable absorbent articlemay be obtained through trial and error and after considering otherdesirable, interdependent properties of the article. In any event, thedegree of cross-linking may be selected by examining the free swellcapacities of the SAP structure, as well as observing the gel strength,AUL and other gross absorbent properties of the structure. Generally,for purposes of description, high cross-linked SAP have free swellcapacities of about 20 to 40 g/g SAP and low cross-linked SAP have freeswell capacities greater than about 40 g/g. SAP materials which aretypically employed in presently available absorbent products may beconsidered high cross-linked SAP materials and thus, can be used as areference. It should also be noted that typical SAP granules employed inthese products will have a greater degree of cross-linking at thesurface than internally (below the surface), thereby producing amaterial with a hard coating or surface but which is soft and moreabsorbent on the inside). For example, one available SAP sheet(polyaspartic acid) is characterized by 0.1 to 30% cross-linking (whichis generally high) at the surface and 0.1% to 3.0% internally (which isgenerally low). See, e.g., U.S. Pat. No. 5,461,085, hereby incorporatedby reference.

[0047] Below is a more detailed description of compositions (for theabsorbent composite) preferred for various embodiments of the inventivedisposable article. It should be noted that the SAP components willtypically account for over 70% of the absorbent composite.

[0048] (1) SAP Surface Linkage Density. Various types of SAP materialsare available and primarily distinguishable by their main polymerchains, e.g., by biodegradable or non-biodegradable, salt resistant ornon-salt resistant. In many of the embodiments described herein, anacrylic acid super absorbent polymer is preferred. Absorbent propertiesincluding absorbent capacity, absorbent speed, gel strength of acrylicacid SAP vary according to the types and concentrations of surfacecross-linkage agent. However, it is generally understood to increase thesurface cross-linkage density if a high AUL is desired and to decreasethe surface cross-linkage density if a high free swell capacity isdesired.

[0049] (2) SAP Morphology. SAP is available in fiber-state or particlestate including powder state, consolidated particle state, or in needlestate. (particle state refers to each of the states except fiber-state).The type of fiber-state SAP preferable in many of the embodiments of theinvention will be less than about 10 mm in cut length, but preferablyless than 5 mm. Particle state SAP employed in some of the embodimentsof the invention will be smaller than about 500, μin particle size butpreferably under 400μ.

[0050] (3) Density of SAP. The density of the SAP employed in severalembodiments of the invention will be in the range of about 1.3 to 1.0g/cm². If a high absorbent speed is desired, SAP will typically beapplied at a density of about 0.3 to 0.5 g/m². If low absorbent speed isdesired, the SAP density will be about 0.6 to 0.9 g/m². It should benoted, however, that in some applications it will be desirable to applymixtures of both types (densities) of SAP to achieve a variety ofpurposes.

[0051] (4) Mount volume of SAP. The mount or substrate volume of SAPemployed in various embodiments will vary according to the particularapplication, and more specifically, where it is applied in the diaper.Generally, the SAP mount volume will be the following: Absorbent Core:150˜500 g/m²  Back Sheet: 20˜500 g/m² Back Sheet/Absorbent CoreComposite: 50˜500 g/m² Top Sheet/Absorbent Core Composite: 50˜500 g/m²Containment Walls: 20˜100 g/m²

[0052] (5) Nonwoven substrate. From many of the embodiments describedherein, the nonwoven substrate onto which the SAP layer is applied, ispreferably spunbond and SMS(spunbond/meltblown/spunbond)(S1/M/S2)(although S1/M/M/S2 may bepreferred in some embodiments). Preferably, different types of spunbondform the upper (S1) and lower (S2) layers. Generally, S1 should be acoarse denier and have a fluffy structure of spunbond. S2 (which may beprovided as a supporting layer) should be a fine denier and have a densestructure of paper like spunbond. A middle layer of meltblown shouldhave a structure which would adhere on both sides.

[0053] For a backsheet application, it is desirable to have a waterresistance of over 200 mm/Aq of at least 200 mm/Aq but preferably about400 mm/AQ, such that the SMS (whose ratio is between the M layer and theS2 layer) is high. The total basis weight of the SMS is preferably inthe range of about 20 to 45 g/m² and its three components is preferablyincluded in the following: 5˜15 g/m² S1; 5˜10 g/m² M; and 10˜20 g/m² S2.

[0054] (7) Absorbent core and topsheet/absorbent core composites. Forthese composites, a high concentration or ration of S1 is preferable sothat a large amount of SAP may be mounted, but should have a lowerconcentration or ratio of M and S2. For example, the following ratios orconcentrations will be preferred in many of the embodiments of thiscomposite: 10˜15 g/m² S1; 0˜5 g/m² M (note that if the concentration ofM is 0, the composite is composed only of spunbond); and 5˜10 g/m² S2.

[0055] (8) Containment wall and containment wall/absorbent corecomposite. Since the containment wall should be water-resistant (such asthe backsheet), similar compositions will be applied in this embodiment.However, the containment walls are generally thinner than the backsheetbut will preferably have a high ratio between M and S2. The following isone composition suitable for this embodiment of the invention: 4˜5 g/m²S1; 5˜7 g/m² M; and 5˜7 g/m² S2.

[0056] Generally, the prefabricated absorbent composite sheet 200employed in the various embodiments of the invention is characterized bya higher SAP content than is conventional, super absorbency, ultralightweightness, thinness, compactness and stable absorbency due to themicrofibril.

[0057]FIG. 2 is a perspective view of a disposable absorbent article 10in the form of a diaper 10. FIG. 3 illustrates a composite web structureof the diaper 10 in a generally flat and unfolded configuration whichthe diaper 10 assumes during one point in the manufacturing process(when it is stretched in the longitudinal direction). As will beexplained further below, the web structure may be subsequently trimmed,folded, sealed, welded and/or otherwise manipulated to form a disposablediaper 10 in a finished or final form. To facilitate description of thediaper 10 embodying the invention, the description refers to alongitudinally extending axis AA, a laterally extending central axis BB,a pair of longitudinally extending side edges 90, and a pair of endedges 92 which extend between side edges 90 (see FIG. 3). Along thelongitudinal axis AA, the diaper 10 includes a first end region or frontwaist region 12, a second end region or back waist region 14, and acrotch region 16 disposed therebetween. Each of the front and back waistregions 12, 14 is characterized by a pair of ear regions or ears 18,which are located on either side of a central body portion 20 and extendlaterally from the side edges 90. A fastening structure 26 (e.g., aconventional tape fastener) is affixed to each of the ears 18 along theback waist region 14 of diaper 10.

[0058] As shown in FIG. 3, the diaper 10 is characterized by a generallyhourglass shape wherein an intermediate portion of side edges 90(generally in the area of the crotch region 16) is biased generallyupwardly (i.e., to partially form upwardly disposed longitudinal walls34). When the diaper 10 is worn about the waist, the front waist region12 is fitted adjacent the front waist area of the wearer, the back waistregion 14 is fitted adjacent the back waist area, and the crotch region16 fits about and underneath the crotch area. To properly secure thediaper 10 to the wearer, the ears 18 of the back waist region 14 arebrought around the waist of the wearer and toward the front and intoalignment with the ears 18 of the front waist region 12. The securingsurface may be located on or provided by the interior or exteriorsurface of the front waist region 12. Alternatively, the fasteners 26may be located on the ears 18 of the front waist region 12 and madesecurable to the ears 18 of the back waist region 14.

[0059]FIG. 4 is an exploded view of the diaper in FIGS. 2 and 3. Adiaper structure suitable for the present invention typically employs atleast four layers. These four layers include a backsheet 60, anabsorbent core 46, an acquisition layer 48, and a topsheet 50. Thediaper structure also includes a pair of containment walls or leg cuffs34 disposed upwardly from the topsheet 50 and preferably equipped atleast with one or more spaced apart, longitudinally elastic members 38.It will be shown below that any of these diaper elements or acombination of these elements may be constructed with or using theprefabricated absorbent composite 200.

Backsheet

[0060] The diaper 10 employs a backsheet 60 that covers the core 46 andpreferably extends beyond the core 46 toward the side edges 90 and endedges 92 of the diaper 10. In one aspect of the invention, the inventivebacksheet 60 is constructed from a single-layered material sheet of aprefabricated absorbent composite 200. As discussed above, such amaterial sheet includes a low density, absorbent layer 208 of hydratablefine fibers in the form of microfibril 204 obtained from cellulose or aderivative thereof and absorbent polymer particles 202 (SAP) intermixedin and bonded together by the microfibril 204 (see FIG. 1). Thisabsorbent layer 208 is applied as a coating on a nonwoven SMS substrate206. Preferably, fine particles (e.g., <100 mm) of a soft, lowcross-link (i.e., fast absorbent rate) or low gel strength SAP isprovided, such that the SAP is adapted to gel block on the nonwovensubstrate upon wetting (see earlier discussion). The nonwoven substrateside of the composite sheet 200 is positioned as an outer surface of thebacksheet 60, while the SAP side of the sheet 200 is positioned as aninner surface of the backsheet 60 and faces the absorbent core 46. Thenonwoven substrate 206 may be provided with printed graphics as is knownin the art.

[0061] To render a backsheet impermeable according to the invention,various inter-dependent variable or properties may be considered. Alower gel strength SAP (e.g., provided by lower cross-linking or otherconstruction practices) causes the gel particles (i.e., the swollen,wetted SAP particles) to “fit together” thereby preventing leakage ofthese particles through the “joints” of the sheet structure. It shouldbe noted, however, that too low of a gel strength can cause the gelparticles to ooze out of the sheet under pressure (and, thereafter,allow liquid to pass through the sheet). Alternatively, a higher AUL SAPwill cause swelling gel particles to press against one another andresist passing of liquid therethrough.

[0062] Additionally, the size of pores in the substrate, the basisweight of the SAP and of the substrate, and higher free swell SAP (whichcorrelates with cross-linking) will affect thepermeability/impermeability of the inventive backsheet. The netinventive result is a backsheet which, upon activation, exhibits auseful rising column strike through (RCST) without leaking. An RCSTvalue as low as about 2 inches may be adequate for the inventivedisposable article, although values closer to about 36 inches willprobably ensure prevention of blotting through (i.e., when the wearersits down on the article) and therefore, are more preferable.

[0063] Accordingly, a backsheet of the inventive disposable absorbentarticle is relatively thin and provides improved flexibility. When dry,the backsheet is soft and breathable, but upon wetting, a thin, gelblocked layer is formed (i.e., on the inner surface of the backsheet)which renders the backsheet substantially liquid impervious.

[0064] In yet another aspect of the invention, the thin, liquidimpervious gel layer is formed (upon wetting) between the absorbent core46 and the nonwoven material, thereby eliminating the need of atraditional, poly-film layer under the core (e.g, on the backsheet atthe crotch region). However, unlike the prior art disposable absorbentarticle that employs a poly-film layer, that area of the inventivearticle is normally breathable (i.e., when wet) and more flexible andcomfortable. Moreover, due to the elimination of the poly-film layer, athinner, simpler diaper structure is produced.

[0065] The absorbent composite 200 for the backsheet 60 in the Figurespreferably employs SAP in a concentration of about 20 g/m² to 100 g/m²suspended in MFC. The absorbent composite 200 also employs a nonwovenlayer of spun bond/melt blown/spun bond (SMS) having a total basisweight of about 20 to 45 g/m².

Topsheet

[0066] When the diaper 10 is worn, the topsheet 50 is placed in closeproximity to the skin of the wearer. The topsheet 50 is preferably soft,compliant, exhibits good strikethrough and a reduced tendency to rewetfrom a liquid pervious material. In this way, such a topsheet 50 permitsbodily discharges to rapidly penetrate it so as to flow toward the core46 more quickly, but not allowing such discharges to flow back throughthe topsheet 50. The topsheet 50 may be constructed from any one of awide range of liquid and vapor permeable hydrophilic materials. Thetopsheet 50 may consist of or include nonwoven webs of natural fibers(e.g., wood or cotton) or synthetic fibers (e.g., polypropylene orpolyester), or a combination of such webs or fibers, or apertured film.

[0067] One topsheet material suitable for the inventive garment is a 15g/m² spun bond polypropylene available from Avgol nonwovens of Holon,Israel. The surface (s) of the topsheet may be treated with a surfactantso as to facilitate liquid transfer therethrough, especially at acentral zone or area of the topsheet located over the core and an innersurface of the core. The topsheet may also be coated with a substancehaving rash preventing or rash reducing properties (e.g., aloe vera).

[0068] In one embodiment, the topsheet 50 is formed from asingle-layered material sheet that covers substantially the entire areaof the disposal absorbent article 10, including substantially all of thefront waist region 12, back waist region 14, and cross regions 16.Further, the ear layer of the inner region 18 is formed from the samesingle topsheet material and, thus, may be referred to as being unitarywith the topsheet 50 in forming lateral extensions of the topsheetmaterial. Alternatively, the topsheet 50 may be formed from multipledifferent materials which vary across the width of the topsheet 50 sucha multiple piece design allows for creation of preferred properties anddifferent zones of the topsheet.

[0069] Referring now to FIG. 5, in one particular embodiment of theinvention, the topsheet 50 is raised or spaced, at least partially,above the core 46 by a plurality of longitudinally extending elasticstrands 102. The strands 102 form spaced apart ridges 152 on thetopsheet 50 in valleys or depressions 154 between the ridges 152. Thevalleys 154 are tacked down to the core 46 at bond points 106 or to theacquisition layer (not shown). Such a “tented” topsheet 50 directsliquid received therein into the valleys or depressions 154. As will befurther explained below, the core 46 according to the invention ispreferably constructed from the prefabricated absorbent composite 200.The core 46 is designed to absorb liquid received below the topsheet 50and to swell upon wetting such that the SAP fill the zones or voidsunder the topsheet 50 (see FIG. 6). The swelling SAP also furtherreinforces the three-dimensional tented structure. Preferably, the core46 is comprised of a plurality of longitudinally-extending, laterallyspaced-apart core segments (see description of core structures below)each of which are disposed under the “tented” topsheet (i.e., in thevoid areas). Alternatively, the core 46 may be a single sheet structurehaving distinctly higher SAP concentrations in the void areas than alongthe bond points (see FIGS. 6 and 7). Variations of this type of coredesign, each of which is suitable for the “tented” topsheetconfiguration, are discussed further below.

[0070] In any one of the embodiments of inventive disposable absorbentarticle, the SAP absorbent layer may be coated with a miscible,hydrophobic material. The coating acts as a barrier or membrane thatinitially slows the liquid uptake, thereby saving SAP capacity foradditional or secondary discharges. In this regard, the coating evensout the absorbency rates between discharges. The coating may take theform of any type of miscible, hydrophobic material film or membrane.

[0071] In one embodiment, a light coating of mineral oil is applied overthe SAP absorbent layer (e.g., over the surface of the SAP granules).The coating retards the initial uptake of the SAP and allows more timefor the liquid to spread out in the article. Preferably, the mineral oilis applied at a concentration of about 0.11 g/g of SAP to about 1.0 g/gof SAP (depending on the particular product design). Alternatively, themineral oil may be applied in specific target zones. In this way, thereceived liquid is encouraged to initially spread to uncoated areasbefore the coated areas are activated and begin to swell.

[0072] In one embodiment, the prefabricated absorbent composite 200includes a topsheet layer (e.g., over the low density layer 206). Theprefabricated absorbent composite 200 is disposed in the crotch regionof the disposable absorbent article (i.e., over the backsheet andprovides both the topsheet and core (i.e., in one material sheet) forthe article. The topsheet or a section thereof may also provide thenonwoven substrate 206 for the absorbent composite 200.

Absorbant Core

[0073] An absorbent core 46 employed by the disposable absorbent article10 according to the invention is preferably constructed with theprefabricated absorbent composite 200 (previously discussed). Moreparticularly, such an absorbent composite 200 for the core 46 typicallyconsists of a relatively high loft, nonwoven material coated with asuper absorbent polymer structure. A core according to the invention istherefore, nearly as thin as a typical nonwoven substrate raw material,but has an SAP basis weight found in a regular diaper core. FIGS. 7-12depict various embodiments of the invention, wherein the above describedabsorbent composite 20 is utilized as the primary or unitary element ofthe core structure, and wherein like elements are identified by likereference numerals. As shown in these drawings, the inventive core 46may employ a uniform layer of the absorbent composite 200, a non-uniformstructure layer in which the low density SAP layer is applied in asegmented layer or in, otherwise, distinct space-apart zone layers, inmulti-tiered layers, or in other variations.

[0074] Each of FIGS. 7-9 depicts a continuous sheet 700, 800, 900(including a core structure) constructed of a prefabricated absorbentcomposite having a plurality of distinct, spaced-apart or segmented SAPconcentrations or layers deposited on a nonwoven substrate.

[0075] The plan view of FIG. 7 depicts a composite structure 700 (andprefabricated absorbent composite) in which the low-density SAP layersor concentrations (with MFC) is applied over a nonwoven substrate 703 inlongitudinally-extending segments. Such a design provides uncoated bandsor zones 701 between the SAP segments 705. The wicking zones 101 areparticularly adapted to wicking (i.e., wicking zones 701) and allow theSAP. segments 700 freedom to expand or wick in the lateral directionswithout gel blocking. In this manner, the absorbent capacity of the SAPis maximized or fully utilized. More specifically, this segmented designensures that the SAP layer will be fully wetted out and also reducespressure between the SAP particles (thereby allowing liquid to flowtherebetween and promoting complete saturation). Preferably, the widthof the core segments 705 is in the range of about 1-15 mm, and thewicking zones have a width in the range of about 1-25 mm.

[0076] In the embodiment depicted in the plan view of FIG. 8, thecomposite structure 800 (or prefabricated absorbent composite) includesa nonwoven substrate layer 803 onto which distinct, spaced-apart SAPconcentrations or SAP layers 805 are applied. The SAP concentrations areformed by distinct dotted or rounded layers 805 of the high-density SAPmaterial and MFC. Similar to the longitudinally-extending segmentedlayer design of FIG. 7, the spaces between the dots 805 are uncoatedwicking zones 801 which allow the SAP dots 805 freedom to expand or wickin all directions without gel blocking. Again, such a design allows fullutilization of the absorbent capacity of the SAP by ensuring completewetting and reducing the pressure between the SAP particles. Preferably,the SAP dots 805 will have diameters in the range of about 2 to 20 mm,and are spaced from one another by an average distance of about 1 mm to10 mm. Also, the arrangement of the SAP dots 805 is preferably astaggered pattern as shown in FIG. 8, such that the areas of the wickingzones 801 are generally uniform and equally maximized.

[0077]FIG. 9 depicts yet another composite structure 900 embodying avariation of the segmented absorbent core according to the invention.The spaced-apart segmented SAP layers 903 each has a high SAPconcentration section 903 a and are applied onto a nonwoven substrate905. In one respect, such a design may be described as providing highconcentration SAP target areas, wherein the core exhibits higherabsorbent capacity due to the higher SAP concentration. For example, inFIG. 9, the high concentration or wider SAP sections 903 will bestrategically positioned in the central crotch region. It should benoted that such target areas may utilize not only segmented SAP layersof various shapes and sizes, but also uniform, multi-layered ormulti-tiered layer designs as well (see e.g., FIGS. 10-12).

[0078]FIG. 10 depicts yet another composite structure 1000 embodying avariation of the inventive core wherein a high SAP concentration isprovided in the central crotch region 16. The absorbent core 46 employsa multi-tiered absorbent composite structure, and more specifically, asmaller secondary absorbent composite layer 1002 applied over the largerfirst absorbent composite layer 1001. In further embodiments, thesecondary absorbent composite layer 1002 may be replaced with highconcentrations of spaced-apart, longitudinally-extending segmentedlayers, dotted layers, and the like, so as to achieve higher absorbentcapacity in the target area, i.e., crotch region. The compositestructure 1000 in FIG. 10 also utilizes a bottom or substrate layer1007, e.g., a backsheet.

[0079] The vertical cross-sectional view of FIG. 11 depicts yet anothercomposite structure 1100 embodying a variation of an absorbent coreaccording to the invention, and which employs a prefabricated absorbentcomposite disposed in a corrugated configuration. As shown therein, anabsorbent composite 1105 is folded into multiple “V” structures 1103made up of two folds or sections 1102 having flexible gaps therebetween.The folds 1102 are glued together at bond points 1101 so as to keep thepleated layers or “V” structures 1103 attached to one another. Such acorrugated structure serves the auxiliary function of increasing thesurface area of the absorbent composite, thereby increasing the speed ofliquid flow into the absorbent materials and increasing the absorbentcapacity of the core. In a relatively wide diaper in the prior art, whenthe diaper is worn, the absorbent core folds into a “V” between thewearer's legs, and the absorbent materials of the core are held somedistance away from the wearer. In the corrugated core design of FIG. 1,the multiple small “V” folds 1103 hold the core closer to the wearerthan one single, large “V” fold. In this manner, a relatively narrowcore is produced which moves dynamically with the wearer, rather thanmove away from the wearer (as in the prior art).

[0080]FIG. 12 depicts yet another composite structure 1200 embodiment ofthe inventive disposable absorbent article according to the invention.In this embodiment, the article employs an absorbent composite structure1200 as an absorbent core 1200 configured in a nested doll structure.The nested doll core, includes a prefabricated sheet of absorbentcomposite 1240 that is rolled substantially about a pulp concentration1230. The pulp concentration 1230 provides wicking and facilitatesliquid distribution, while the prefabricated absorbent sheet 1240provides structural integrity. It should be understood that theabsorbent layer 1240 may employ multiple sheets or layeredconfigurations as discussed before. For example, the uniform sheet layerin FIG. 12 may be replaced with or supplemented by segmented layers ofSAP concentrations similar to those shown in FIGS. 7-9.

[0081] Moreover, the core according to various embodiments of theinvention may be configured to extend substantially the full lengthand/or width of the disposable absorbent article. Preferably, however,the core is disposed or is otherwise concentrated at the crotch regionof the article. In various embodiments, the core includes a sheet orlayer that extends to the edges of the article and an absorbentcomposite(s) is concentrated in the crotch region or another target zoneof the article.

[0082] The core may also include additives which provide specificproperties for the article. For example, baking soda may be added toprovide improved odor absorbency. Further, a nonwoven sheet may be addedto provide added flexibility and stretchability.

Backsheet/Absorbent Core Composite

[0083] Each of FIGS. 17-19 depicts a backsheet/absorbent core composite1700, 1800, 1900 utilizing the prefabricated absorbent composite sheet200. In these embodiments, the backsheet and absorbent core composite1700, 1800, 1900 replaces the traditional backsheet-poly-filmbarrier-absorbent core assembly in the prior art. Referring to FIG. 17,the backsheet 1701 is formed by an SMMS and SMS liquid barrier layercombination 1701 that extends beyond the crotch region of the article 10and preferably to the edges of the article 10. In the crotch region 16of the article 10, an absorbent composite of the SMS nonwoven substrate1701 and a low-density, high SAP content absorbent layer 1703 together(i.e., applied by hot melt adhesion over the substrate 1701) forms theabsorbent core. In FIGS. 17 and 19, the crotch region 16 of the article10 is provided with a single, uniform layer of the absorbent composite1700, 1900 including an absorbent layer 1703, 1833 preferably having anSAP content about 180 g/m². In the composite 1900 of FIG. 19, a secondSMS and SMMS combination layer 1907 is added (e.g., by hot melt) to thecomposite for extra leakage protection.

[0084] In FIG. 18, a plurality of segmented, elongated high SAP content(e.g., about 120 g/m²) absorbent composite layers 1803 are provided inthe crotch region 16 to form the core. Preferably, the SMMS backsheetlayer 1801 forms about the rounded contour of the absorbent compositesor cores 1803, thereby creating pockets or channels in which theabsorbent composites 1803 are disposed.

[0085] Each of FIGS. 20 and 21 depict a topsheet/absorbent corecomposite structure that may be utilized in a disposable absorbentarticle 10 according to the invention. These designs eliminate the needfor the traditional three component design of a topsheet, acquisitionlayer and absorbent core structure, and provides instead a single layerof topsheet and absorbent core composite. In a first embodimentillustrated in FIG. 20, the absorbent composite 2000 includes atwo-layer nonwoven with an SAP coating. The two-layer nonwoven ispreferably provided in a concentration of about 35 g/m², while the SAPis preferably provided in a concentration of about 150 g/m².

[0086] The two-layer nonwoven consists of a fine PE/PET bicomponentfiber layer 2003 and an PET/Rayon layer 2001. The PE/PET bicomponent ispreferably at about 1.5 denier, thermobonded, and has a basic weight ofabout 10 g/m². The PET/Rayon layer 2001 is preferably 50% PET and 50%Rayon, wherein the PET is at about 5 denier and the Rayon is at about1.5 denier. Together, the PET/Rayon mixture is preferably in aconcentration of about 25 g/m². As shown in FIG. 20, the two-layernonwoven is preferably immersed in an SAP slurry coating to produce thecomposite 2000. Note that the SAP particles 2005 are positioned belowthe PE/PET and on the underside of the composite, thereby providing theabsorbent core of the disposable absorbent article 10 of the invention.

[0087]FIG. 21 illustrates a second embodiment of a topsheet/absorbentcore composite structure that may be utilized in an inventive disposableabsorbent article 10. FIG. 21 also illustrates the components which makeup the composite structure and how such components are combined toproduce the composite structure. Generally, the composite structure 2100includes a nonwoven layer 2102 that is preferably a thermal bondedPE/PET bicomponent at 3 denier and a basis weight of 40 g/m². The SAPslurry (which provides the SAP) is preferably at a concentration ofabout 150 g/m² and is coated in a segmented fashion (to the nonwovenlayer 2106) to form a plurality of absorbent layers 2104. Then, theabsorbent composite 2100 may be folded between the absorbent layersegments 2104 and elastic elements 2106 added so as to form a tentedstructure. Elastic elements 2106 are preferably provided underneath thetopsheet at a location corresponding to the peaks thereof. The absorbentcomposite 2100 is preferably fixed to the backsheet 2108 by, forexample, hot melt adhesion. It should be apparent that this tentedstructure employing the absorbent composite structure 2100 provides arelatively thin absorption area, but one having an increased surfacearea.

Containment Walls

[0088] Now turning to FIGS. 13 and 14, in yet another aspect of theinvention, the inventive disposable absorbent article 10 utilizes a pairof containment walls or cuffs 34 which employ a prefabricated absorbentcomposite 200. Each containment wall 34 is a longitudinally extendingwall structure preferably positioned on each side of the core 46 andspaced laterally from the longitudinal center. The longitudinal ends ofthe walls 34 may be attached, for example, to the topsheet 50 in thefront and rear waist regions 12, 14. Preferably, the ends of thecontainment wall 34 are tacked down inwardly and attached, for example,by adhesive to the web structure 10 a. Such a construction effectivelybiases the containment wall 34 inwardly and is generally considered tocause containment wall 34 to exhibit improved leakage preventionproperties.

[0089]FIG. 13 provides a vertical cross-sectional view of a diaper 10according to the invention. The diaper 10 includes backsheet 60,absorbent core 46, acquisition layer 48, and topsheet 50. The diaper 10also includes a pair of containment walls or cuffs 34 which are formedby folding topsheet 50 and wrapping it about a prefabricated absorbentcomposite 1300. The width of the absorbent composite 1300 may generallyequal the height of the containment walls 34, while the length of theabsorbent composite sheet 1300 may extend the full length of diaper 10(or at least through the crotch region 16). Furthermore, the containmentwalls 34 may be biased inwardly toward the center.

[0090] Preferably, the containment walls 34 are equipped with elasticmembers 38, which extend along a substantial length of the containmentwalls 34. In a common application, the elastic members 38 are placedwithin the containment walls 34, preferably at the top of thecontainment walls 34 while in a stretched condition and then glued tothe containment walls at least at their ends. When released or otherwiseallowed relaxing, the elastic members 38 retract inwardly. When thearticle 10 is worn, the elastic members 38 function to contract thecontainment walls 34 about the buttocks and the thighs of the user in amanner, which effects a seal between the article 10, the buttocks andthe thighs.

[0091]FIG. 13 depicts the configuration of the containment walls 34 whenit is soft and dry. FIG. 14, on the other hand, depicts the containmentwalls after wetting, in which the absorbent composite 1300 (i.e, theSAP) has swollen to dispose the containment walls 34 in a resiliently,erect position. Unlike traditional leg cuffs in the prior art, theresiliently erect containment walls 34 resists flattening (e.g., whenthe wearer sits down) and, thereby, ensures leakage prevention,especially of explosive, liquefied bowel movements and rapid dischargesof urine.

[0092] In a further embodiment of the invention, the disposableabsorbent article may employ multiple containment walls, including innercontainment walls which are shorter than outer containment walls (closerto side edges 90).

[0093]FIG. 15 depicts yet another variation of the inventive disposableabsorbent article 10. The article 10 includes containment walls 34 andan absorbent core formed from a continuous piece of prefabricatedabsorbent composite 1500. The absorbent composite 1500 includes threeSAP sections 1500 a with a non-SAP coated band along their intersections(GG). Note that the intersection GG corresponds to the location wherethe single continuous prefabricated sheet 1500 is folded. As describedabove, the containment wall 34 which contains the prefabricatedabsorbent composite sheet 1500, stays soft when dry (FIG. 15), butswells to a resilient erect position when wetted (FIG. 16). Accordingly,the containment walls 34 resist being flattened, like traditional legcuffs, when the wearer is in the sitting position, thereby helpingprevent leakage.

[0094] Each of FIGS. 22-24 depicts the use of the prefabricatedabsorbent composite 2200, 2300, 2400 in the construction of the leggathers (i.e., another type of containment wall) of a disposableabsorbent article 10 according to the invention. In FIG. 22, a materialsheet of the absorbent composite 2200 is used to form the upstandingcontainment walls or cuffs, wherein the segmented high SAP contentabsorbent layers 2201 are disposed inwardly to face the crotch region).Conversely, the nonwoven substrate 2203 is located on the outside oroutboard of the crotch region.

[0095]FIG. 23 depicts an alternative embodiment of the leg gathersemploying an absorbent composite 2300, according to the invention. Theabsorbent composite employed in this embodiment is similar to thatillustrated and described with respect to FIG. 20 (above). Further, inthis embodiment, an absorbent composite is also provided (e.g., with thebacksheet 60 as to the nonwoven substrate) as the absorbent core of thediaper.

[0096]FIG. 24 depicts yet another variation of a use of the absorbentcomposite 2400 in a disposable absorbent article 10 of the invention. Inthis embodiment, a conventional backsheet 60 provides the nonwovensubstrate for each of the three absorbent composites. The absorbentcomposites 2400 provides not only the core structure, but an absorbentlayer 2401 for each of the cuff structures.

Optional Layers

[0097] The disposable absorbent article according to the invention mayemploy additional layers including an acquisition layer or surge layer,preferably situated between the topsheet and the core (e.g., FIG. 4).One function of such an acquisition layer is to spread out or disperseliquid flow so that liquid is distributed more evenly over the coresurface. This serves to slow down the flow so that the liquid hasadequate time to be absorbed by the core. The acquisition layer alsoserves to prevent the core from being saturated locally, while asubstantial remainder of the core is not absorbing any liquid.

[0098] The acquisition layer may be constructed from the absorbentcomposite 200. More specifically, the acquisition layer 48 may beprovided by a sheet of the absorbent composite 200 with an SAP having ahigh gel strength and a high loft substrate. Such an acquisition layersheet advantageously becomes more porous upon wetting. This property isfurther improved by providing a high loft nonwoven substrate such asthrough-air bonded nonwovens or any other standard acquisition layerproduct. Accordingly, typically, dual layers—an acquisition layer and adistribution layer—are employed in the prior art. However, in thepresent invention, the acquisition layer is provided by the single sheetacquisition layer constructed from the absorbent composite 200. With theinventive acquisition layer constructed from the absorbent composite200, very stiff granules within the sheet expand upon wetness andprovides pores or passages through the sheet (rather than collapsing).

Tape Tabs

[0099] The disposable absorbent article must be secured to the wearer.This is most important with respect to diapers since diapers are notpulled up by the wearer, like training pants or incontinent briefs, butare fastened around the wearer. Securing elements compliment the elasticmembers by effecting a quasi-seal between the wearer and the waistbandand leg cuffs, so that liquid is contained within the article which isthen absorbed; in other words, so that it does not leak through gasbetween the wearer and the edge of the article. The securing elementsmay be adhesive, mechanical fasteners hook and loop features, orconceivably strings, i.e., anything that will secure one end of thearticle to the longitudinally opposite end.

[0100] In the embodiments shown in the Figures (see, e.g., FIG. 4), thearticle 10 is affixed to the wearer by tape fasteners 26 which arepermanently affixed to (e.g., sewn directly into) the backsheet 60. Tapefasteners 26 are contacted with the transversely opposite ear 22extending from the backsheet, where they remain affixed due to adhesivecompound applied to the fasteners 26.

Waistband

[0101] Waistbands employing elastic members are positioned along thetransverse portion of the article 10 so that when worn, the waistbandsare positioned along the waist of the wearer. Generally, the waistbandpreferably creates a quasi-seal against the waist (transverse elasticmembers 52) so that liquid waste does not leak from the regions betweenthe waist elastic and the waist of the wearer. The quasi-seal issignificant because although the liquid may be eventually absorbed byfiller material, the assault of liquid by the wearer may overwhelm theabsorption rate capacity of the filler material. Hence, the waistbandscontain the liquid while it is being absorbed. Secondly, the waistbandspreferably has a capacity to absorb liquid (see, e.g., U.S. Pat. No.5,601,544, which is hereby incorporated by reference).

Article's Shape

[0102] The shape of the article can provide certain attributes. Anarticle providing a more precise contour around the wearer's crotch areawill less likely bunch up. In this way, The article helps to preventpools of liquid from building up and locally saturating underlyingfiller material. The article's shape can also be manipulated to controlthe seal or the closure of gas between the edges of the article and thewearer. A narrower profile may be desirable to achieve a smooth liquidcontact zone against the wearer's crotch (i.e., no bunching). However, anarrower profile also means less surface area available for fillermaterial thereby decreasing the article's absorption capacity.Similarly, a larger profile can more readily accommodate a variety ofsizes, whereas a narrower profile may not be suitable for largerwearers. However, a larger article may be more costly to manufacture andrequire a higher ticket price.

[0103] The present invention is, therefore, well adapted to carry outthe objects and attain the ends and the advantages mentioned, as well asothers inherent therein. While presently preferred embodiments (in theform of a diaper) have been described, numerous changes to the detailsof construction, arrangement of the article's parts or components, andthe steps to the processes may be made. For example, the varioustopsheets, backsheet, absorbent core, containment walls and otherabsorbent composite structures may be utilized in other parts of thearticle or with other articles other than diapers. Such changes willreadily suggest themselves of those skilled in the art and areencompassed within the spirit of invention and in the scope of theappended claims.

What is claimed is:
 1. A disposable absorbent article comprising: a topsheet; a backsheet; and an absorbent core disposed therebetween; wherein at least one of said backsheet, topsheet, and absorbent core is constructed of an absorbent composite including an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and super absorbent polymer (SAP) particles bonded together by said hydratable fibers, and a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon.
 2. The article of claim 1, further comprising a pair of longitudinally-extending, upstanding cuffs spaced laterally from said core, each said cuff including a folded portion of said topsheet and a longitudinally-extending absorbent composite secured within said folded portion, said longitudinally-extending absorbent composite including an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and super absorbent polymer (SAP) particles bonded together by said hydratable fibers, and a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon.
 3. The article of claim 2, wherein said core includes said first absorbent composite.
 4. The article of claim 3, wherein said first absorbent composite and said longitudinally extending absorbent composites of said cuffs are sections of one continuous absorbent composite structure positioned about a crotch region of said article.
 5. The article of claim 2, wherein said nonwoven substrate is a section of said topsheet.
 6. The article of claim 1, wherein said backsheet is formed from said absorbent composite, said absorbent layer including a low cross link SAP adapted to gel block upon wetting such that said backsheet is substantially impervious when wet and said backsheet is breathable when dry.
 7. The absorbent article of claim 6, wherein said SAP are water-swellable particles included in a concentration in the range of about 50 g/m² to about 500 g/m².
 8. The absorbent article of claim 1, wherein said absorbent core includes a prefabricated sheet of said absorbent composite.
 9. The absorbent article of claim 8, wherein said absorbent composite of said core includes a plurality of said absorbent layers, said layers being spaced apart form one another such that non-coated surface sections of said substrate are exposed therebetween.
 10. The absorbent article of claim 9, wherein said non-coated surface sections form wicking zones between said absorbent layers.
 11. The absorbent article of claim 8, wherein said absorbent layers are laterally spaced, elongated segments.
 12. The absorbent article of claim 8, wherein said absorbent composite layer has a corrugated configuration characterized by a plurality of pleats at which distinct adjacent sections of said absorbent composite are mutually adhered.
 13. The absorbent article of claim 1, wherein said absorbent composite forms said backsheet and said core, said backsheet having a section providing said nonwoven substrate and said absorbent layer being concentrated at a crotch region of said backsheet to form said absorbent core.
 14. The absorbent article of claim 1, wherein said core includes said absorbent composite, said absorbent composite further including one or more of said absorbent layers disposed over said nonwoven substrate.
 15. The absorbent article of claim 1, wherein said absorbent composite further includes a concentration of pulp material, said absorbent layer and said nonwoven substrate forming a sheet disposed about said pulp concentration such that said pulp concentration is disposed between at least two layers of said sheet of absorbent layer and nonwoven substrate.
 16. The absorbent article of claim 1, wherein said absorbent composite forms at least a portion of said topsheet and said absorbent core, said topsheet having a section providing said nonwoven substrate and said absorbent layer forming said core.
 17. The absorbent article of claim 1, wherein said absorbent layer includes low-crosslink, low gel strength SAP having free swell capacities of over 40 g/g and such that said absorbent layer is adapted to gel block upon wetting so as to be substantially impervious but is breathable when dry.
 18. A disposable absorbent article comprising: a topsheet; a backsheet; an absorbent composite including an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and absorbent polymer (SAP) particles bonded together by said hydratable fibers, and a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon; and wherein said absorbent layer is disposed between the topsheet and backsheet, and generally centrally at a location identified as a crotch region, said absorbent layer providing an absorbent core for absorbing bodily exudates received in said crotch region.
 19. The article of claim 18, wherein said absorbent layer is supported underneath a section of said topsheet, such that said section of said topsheet provides said nonwoven substrate of said absorbent composite.
 20. The article of claim 18, further comprising a pair of longitudinally-extending, upstanding cuffs spaced laterally from said absorbent core, each said cuff including a folded portion of said topsheet and a longitudinally-extending absorbent composite secured within said folded portion, said longitudinally-extending absorbent composite including an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and super absorbent polymer (SAP) particles bonded together by said hydratable fibers, and a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon.
 21. The article of claim 18, wherein said absorbent composite located at said crotch region and said longitudinally extending absorbent composites of said cuffs are sections of one continuous absorbent composite structure positioned about the crotch region.
 22. The article of claim 18, wherein said absorbent layer is supported on said backsheet, such that a section of said backsheet provides said nonwoven substrate of said absorbent composite.
 23. The article of claim 20, wherein said absorbent layer includes a low cross link SAP adapted to gel block upon wetting such that said backsheet is substantially impervious when wet-and said backsheet is breathable when dry.
 24. The absorbent article of claim 18, wherein said SAP are water-swellable bodies included in a concentration of about 20 gsm and said nonwoven substrate is an SMS having a basis weight in the range of about 10 gsm to 60 gsm.
 25. The absorbent article of claim 18, wherein said absorbent composite of said core includes a plurality of said absorbent layers, said layers being spaced apart form one another such that non-coated surface sections of said substrate are exposed therebetween, said non-coated surface sections forming wicking zones between said absorbent layers.
 26. The absorbent article of claim 25, wherein said absorbent layers are laterally spaced, elongated segments.
 27. The absorbent article of claim 18, wherein said absorbent composite layer has a corrugated configuration characterized by a plurality of pleats at which distinct adjacent sections of said absorbent composite are mutually adhered.
 28. The absorbent article of claim 18, wherein said absorbent composite further includes a concentration of pulp material, said absorbent layer and said nonwoven substrate forming a sheet disposed about said pulp concentration such that said pulp concentration is disposed between at least two layers of said sheet of absorbent layer and nonwoven substrate.
 29. The absorbent article of claim 18, wherein a plurality of sections of said topsheet is spaced from said topsheet and alternating sections of said topsheet are secured to said backsheet, each said spaced topsheet section including one or more of said absorbent layers such that said topsheet forms said nonwoven substrate of said absorbent composite.
 30. In a disposable absorbent having an absorbent core disposed between a topsheet and a backsheet, a prefabricated absorbent composite comprising: an absorbent layer of hydratable fine fibers in the form of microfibril obtained from cellulose or a derivative thereof, and absorbent polymer (SAP) particles bonded together by said hydratable fibers, and a nonwoven substrate supporting said absorbent layer, said absorbent layer being coated thereupon; wherein said absorbent layer is disposed between the topsheet and backsheet, and generally centrally in the article at a location identified as a crotch region, said absorbent layer providing an absorbent core for absorbing bodily exudates received by the crotch region.
 31. The absorbent composite of claim 31, wherein said absorbent layer is supported underneath a section of the topsheet, such that said section of topsheet provides said nonwoven substrate of said absorbent composite.
 32. The absorbent composite of claim 30, wherein the article includes a pair of longitudinally-extending, upstanding cuffs spaced laterally from said absorbent core, each cuff having two sheet layers, and wherein said absorbent composite includes two longitudinally-extending composite sections extending upwardly from the crotch region into the cuffs and between the cuff layers, said absorbent composite forming an absorbent structure about the crotch region.
 33. The absorbent composite of claim 30, wherein said absorbent layer is supported on a section of the backsheet, such that said backsheet section provides said nonwoven substrate of said absorbent composite.
 34. The absorbent composite of claim 33, wherein said absorbent layer includes a low cross link SAP adapted to gel block upon wetting such that said backsheet section is substantially impervious when wet and said backsheet section is breathable when dry.
 35. The absorbent composite of claim 34, wherein said low cross-link SAP is low-gel strength SAP characterized by a free swell capacity greater than about 40 g/g.
 36. The absorbent composite of claim 30, wherein said SAP are water-swellable bodies included in a concentration of about 50 gsm to 500 gsm.
 37. The absorbent composite of claim 30, wherein said absorbent composite of said core includes a plurality of said absorbent layers, said layers being spaced apart from one another such that non-coated surface sections of said substrate are exposed therebetween, said non-coated surface sections forming wicking zones between said absorbent layers.
 38. The absorbent composite of claim 30, further comprising a coating of mineral oil over the SAP particles of the absorbent layer, said coating being adapted to retard the initial receipt of liquid by the SAP in the absorbent layer. 